Defender (1993+). Manual — part 44

LT77S MANUAL

GEARBOX

GEAR

SELECTOR

HOUSING

-

TRANSFER

GEARBOX

1. Gaiter retaining Screw - 4 off.

11. Cross shaft.

2. Gaiter.

12. Gear lever.

3.

Gaiter support plate.

13. Gear change housing.

4. Gate plate.

14. Non-metallic bushes.

5. Gasket.

15. Counter sunk screws.

6. Split pin.

16. End cover.

7. Clevis pin.

17. Detent spring and plate.

8. Circlip retaining Nylon seat.

18. Selector fork.

9. Gear lever ball.

19. "O” rings.

10. Nylon seat.

17

REISSUED:

FEB

1993

LT77S

MANUAL GEARBOX

SYNCHROMESH

ASSEMBLIES

Third-fourth and fifth gear synchromesh.

NOTE: The above assemblies are the same

except that fifth gear synchromesh has a retainer
plate.

1. Mark relationship of inner and outer members.

2. Remove wire clip from both sides of

assembly.

7. Examine the dog teeth on all gears for wear

and damage.

NOTE:

Example

"A"

shows a tooth in good

condition. Example

"B"

shows the rounded

corners of a worn tooth.

3. Remove slippers and separate the two

members.

4. Examine all parts for damage and wear

including wire clips for tension.

5. Check no radial movement exists between

inner members and mainshaft splines. (except
fifth gear synchromesh).

6. Examine inner and outer splines for wear.

18

REISSUED: FEB 1993

LT77S MANUAL GEARBOX

First-second synchromesh

12. Fit the slippers and secure with a s

side of the synchromesh.

8. Repeat instructions 1 to 6 for third-fourth

synchromesh.

NOTE:

The hooked end of each spring must

9.

Examine step in each of outer splines.

locate

in the same slipper with the free ends

10. Check that the step on both sides of the

running i n opposite directions and resting

internal splines are sharp not rounded.

against the remaining slippers.

NOTE: This applies only to splines on selector
groove side of member.

13. Assemble

third-fourth

and

fifth

gear

synchromesh components as in instruction 12.

NOTE:

The back plate for fifth gear is fitted to

the rear of the assembly with the single tag

locating in

a slot

in

the inner member.

11.

Fit inner member

to outer

so

that

the wide

splines of inner member are under the spur
gear teeth.

REISSUED:

FEB

1993

19

LT77S

MANUAL

GEARBOX

CHECKING

BAULK

RING

CLEARANCES

Check clearance

of all baulk rings and gears by

pressing the baulk ring against the gear and
measuring the gap, The minimum clearance should
be 0,38mm (0.015in).

First gear